U.S. patent number 4,584,203 [Application Number 06/579,836] was granted by the patent office on 1986-04-22 for dough rolling process for laminated cookies.
This patent grant is currently assigned to The Procter & Gamble Co.. Invention is credited to John G. DuVall, Suzanne L. Hardie, Charles E. Kirby.
United States Patent |
4,584,203 |
DuVall , et al. |
April 22, 1986 |
Dough rolling process for laminated cookies
Abstract
A process for making cookies intended to simulate typical drop
cookies from a plurality of laminated doughs, wherein the
appearance and quality of the cookies is desirably improved by
rolling the cut laminate preforms prior to baking to prevent any
formation of thin, crisp edges upon baking, and to control the
visibility of morsels such as flavored chips.
Inventors: |
DuVall; John G. (Fairfield,
OH), Kirby; Charles E. (Cincinnati, OH), Hardie; Suzanne
L. (Cincinnati, OH) |
Assignee: |
The Procter & Gamble Co.
(Cincinnati, OH)
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Family
ID: |
27044922 |
Appl.
No.: |
06/579,836 |
Filed: |
February 21, 1984 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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475771 |
Mar 16, 1983 |
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Current U.S.
Class: |
426/549; 426/502;
426/94 |
Current CPC
Class: |
A21C
7/04 (20130101); A21C 7/01 (20130101) |
Current International
Class: |
A21C
7/04 (20060101); A21C 7/01 (20060101); A21C
7/00 (20060101); A21D 008/00 () |
Field of
Search: |
;426/94,502,560,549 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2414177 |
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Sep 1915 |
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DE |
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2511847 |
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Sep 1976 |
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DE |
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2073647 |
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Oct 1981 |
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GB |
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Other References
Matz, Bakery Technology and Engineering, 2nd Ed., Westport, Conn.,
AVI Pub. Co. Inc., 1972, pp. 204-205, 354-355. .
Redfern and Hickenbottom, "Levulose-Containing Corn Syrups for the
Baker", The Bakers Digest, Apr. 1972, pp. 26-31. .
Cannon, M., The Fructose Cookbook, Fast & McMillan Publishers,
Inc., Charlotte, N.C., pp. 101-112 (1979). .
Manley, D. J. R., Technology of Biscuits, Crackers & Cookies,
Ellis Horwood Limited, Chichester, England, pp. 269-306
(1983)..
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Primary Examiner: Jones; Raymond
Assistant Examiner: King; Elizabeth A.
Attorney, Agent or Firm: Mayer; Nancy S. Gebhardt; Edmund F.
Witte; Richard C.
Parent Case Text
This is a continuation-in-part of the prior copending patent
application Ser. No. 475,771, filed Mar. 16, 1983 now abandoned.
Claims
What is claimed is:
1. A process for making an improved crumb-continuous cookie having
distributed therein discrete regions of storage-stable crisp
texture and discrete regions of storage-stable chewy texture from a
plurality of cookie doughs, comprising the steps of:
(a) forming a laminate cookie preform from the doughs, wherein said
dough providing a storage-stable chewy texture is within said dough
providing a storage-stable crisp texture;
(b) rolling the preform on a support means within a closed-top
cavity of generally circular shape, said cavity moving about a
predetermined axis of rotation, whereby said laminated dough
preform is caused to rotate about the interior surfaces of said
cavity, to substantially uniformly enrobe at least one dough within
an outer layer of at least one distinct dough;
(c) smearing the outer dough by the rolling step to permit some
morsels contained in the enrobed dough to be partially exposed
through the outer layer of dough; and
(d) baking the rolled preform to yield a baked cookie.
2. A process according to claim 1 wherein the rolling step provides
rolled preforms of substantially hemispherical to substantially
spherical shape in proper alignment for baking.
3. A process according to claim 1 wherein said morsels comprise
flavored chips, raisins, nuts, fruit bits, coconut, or cereal.
4. A process according to claim 3 wherein the rolling step causes
the axis of each dough preform to precess and provides a random
appearance of morsels in the baked cookie.
5. A process according to claim 1 wherein said morsels are
sprinkled on the cookie preform prior to rolling and the rolling
step causes the morsels to penetrate into the outer dough
layer.
6. A process according to claim 1 wherein the cookie preforms are
formed in step (a) by a process comprising the steps of:
(a) forming a sheet of a first cookie dough;
(b) depositing a second cookie dough on the first cookie dough;
(c) placing a third cookie dough over the first dough and second
dough; and
(d) cutting discrete laminated cookies preforms from the
doughs.
7. A process according to claim 6 wherein the first and third
doughs are substantially identical.
8. A process according to claim 6 wherein the second dough is
deposited on the first dough as a sheet.
9. A process according to claim 6 wherein the second dough is
deposited on the first dough as individual discrete pieces or
portions.
10. A process according to claim 9 wherein the first and third
dough layers are cut around the individual discrete deposits of the
second dough.
11. A process according to claim 10 wherein the preforms are cut in
a geometric shape, such that no waste dough results.
12. A process according to claim 11 wherein the geometric shape is
selected from the group consisting of circles, squares, rectangles,
and hexagons.
13. A process according to claim 6 wherein the sheet of first
cookie dough in step (a) is cut into discrete pieces prior to step
(b), and the third cookie dough is placed over the pieces of first
dough and second dough as a sheet.
14. A process according to claim 13 wherein the third cookie dough
of step (c) is also cut into discrete pieces prior to step (c).
15. A process according to claim 6 wherein the third cookie dough
is cut into discrete pieces prior to step (c), and the first cookie
dough is in sheet form.
16. A process according to claim 6 wherein the rolling step
generates an outer layer comprised of the first and third doughs
with a smeared top surface around the enrobed individual deposits
of second dough.
17. A process according to claim 6 wherein the rolling step causes
the axis of each dough preform to precess and provides a random
appearance of any morsels present in the baked cookie.
18. A process according to claim 1 wherein the cookie preforms are
formed in step (a) by a process comprising the steps of:
(a) co-extruding the doughs in a continuous manner; and
(b) cutting the co-extruded doughs into laminated cookie
preforms.
19. A process according to claim 18 wherein the doughs are extruded
in the form of continuous concentric cylinders.
20. A process according to claim 18 wherein the laminated cookie
preforms are formed by cutting the extruded dough into discrete
pieces in a manner to substantially enrobe at least one dough
within an outer layer of at least one distinct dough.
21. A process according to claim 20 wherein the rolling step
generates a uniform outer layer of dough with a smeared top surface
around at least one enrobed distinct dough.
22. A process according to claim 20 wherein the rolling step causes
the axis of each dough preform to precess and provides a random
appearance of any morsels present in the baked cookie.
23. A process according to claim 1 for preventing the formation of
crisp thin edges on laminated cookies comprising:
(a) preparing laminated cookie dough preforms from a plurality of
cookie doughs;
(b) rolling the laminated cookie preforms into substantially
hemispherical to substantially spherical shape to essentially
uniformly enrobe at least one dough within at least one distinct
dough; and
(c) baking the rolled preforms to yield crumb-continuous baked
cookies having distributed therein discrete regions of
storage-stable crisp texture and discrete regions of storage-stable
chewy texture.
24. A process according to claim 23 wherein the rolling is
accomplished by one or more orbiting cups or cavities which cause
the dough laminated preform to roll against the interior surface to
reshape it to a substantially hemispherical to substantially
spherical shape.
25. A process according to claim 24 wherein the rolling causes the
axis of each dough preform to precess and provides a random
appearance in the baked cookie of any morsels present.
26. A process according to claim 25 wherein the morsels comprise
flavored chips, raisins, nuts, fruit bits, coconut, cereal, or
other similar edible pieces.
27. A process according to claim 26 wherein the top surface of the
outer dough is smeared by the rolling step to permit some morsels
contained in the enrobed inner dough to be partially exposed
through the outer layer of dough.
28. A process according to claim 24 wherein morsels are sprinkled
on the cookie preform prior to rolling and the rolling step causes
the morsels to penetrate into the outer dough layer.
29. A process according to claim 1 for rolling dough wherein the
appearance of morsels in baked cookies can be controlled
comprising:
(a) enrobing at least one dough piece containing edible morsels
within an essentially uniform outer layer of at least one distinct
dough to form a dough preform;
(b) smearing slightly the top surface of the dough preform during
rolling to permit some of the morsels in the enrobed dough to be
partially exposed through the outer layer;
(c) causing the axis of each dough preform to precess during
rolling to provide a random appearance of morsels; and
(d) baking the dough preform to yield crumb-continuous baked
cookies having distributed therein discrete regions of
storage-stable crisp texture and discrete regions of storage-stable
chewy texture.
30. A process according to claim 29 wherein the outer dough layer
is comprised of a plurality of doughs.
31. A process according to claim 29 wherein the morsels are
flavored chips, raisins, nuts, fruit bits, coconut, cereal, or
other similar pieces.
32. A process according to claim 29 wherein morsels are sprinkled
on the cookie preform prior to rolling and the rolling causes the
morsels to penetrate into the outer dough layer.
Description
TECHNICAL FIELD
This invention relates to a process for making simulated drop
cookies from a plurality of laminated doughs, wherein the
appearance and quality of the cookies is desirably improved by
rolling the cut laminate preforms prior to baking to eliminate the
formation of thin, crisp edges upon baking, and to control the
visibility of morsels such as flavored chips.
BACKGROUND OF THE INVENTION
Drop cookies can be made using a rotary molder. The rotary molder
provides a drum or belt having cavities of the shape desired for
the cookie to be baked. At one point in the motion of the belt or
drum, these cavities are filled with cookie dough of the desired
formulation. Further travel of the belt or drum of the rotary
molder then transfers the dough in the filled cavities to a moving
belt or band in contact with one in close proximity to it.
Preferential adherence of the dough to the belt or band causes the
dough deposited in the rotary molder cavities to be transferred to
the belt or band, by which they are transported through a
continuous oven for baking.
In the manufacture of other cookies, dough is deposited directly on
the belt or band by extrusion of discrete deposits of dough via
extrusion dies of the desired shape. Still other cookies are made
by co-extrusion processes, by forming a sheet of dough from which
is cut the desired shapes, and, finally, by lamination of already
baked cookie portions with fillings, icings, marshmallow creme, and
the like.
A variety of equipment is available to perform dough forming and
handling during manufacturing processes. For example, U.S. Pat. No.
1,948,870, issued Feb. 27, 1934, and U.S. Pat. No. 1,970,336,
issued Aug. 14, 1934, both to Pointon and Harber and assigned to
Baker Perkins Co., Inc., are directed to dough forming apparatus
comprising open top cups or rings which move in an orbital path to
form a dough piece which is confined therein. A stated objective is
to mold the dough pieces into ball or sphere-like formation by the
employment of a row of molding cups or rings, which are given
orbital balling movements of variable amplitude about the axis of
each cup. A support surface for the dough pieces is positioned
opposite the molding rings and can be periodically advanced
stepwise so that dough pieces rolled by one row of cups or rings
are in position for treatment by the next row of cups or rings.
U.S. Pat. No. 3,225,714, issued Dec. 28, 1965 to Gaskell, discloses
improved moulding rings and closed top cups for use in forming
dough products. The cups appear to be intended for use on apparatus
of the type generally disclosed in the Pointon et al. patents. The
cups are provided with dough-working ribs having a substantial
axial directional component to provide undulations which are so
shaped as to knead or work a dough piece as the cups are moved in a
gyratory motion. The gyratory movement and internal taper of the
cup urges the dough downwardly onto the conveyor so as to assure
its effective molding adhesion thereto, while the ribs on the
interior of the cup work over the external surface of the dough,
leaving air spaces between the dough and the ribs, which reduce any
tendency of the dough to stick to the mold. A multiple cup unit for
carrying a plurality of detachable cups of various sizes is also
described.
While it is clear from the foregoing and other, similar references
that methods and apparatus for rolling pieces of dough-like product
are known in the art, it is significant that none of the foregoing
references are directed to the rolling of laminated dough pieces
wherein the objective is to simulate drop cookies, such as made by
the rotary molder technique. It is also significant that none of
the foregoing references are directed to multi-layer products,
wherein the objective is to provide substantially uniform
encapsulation of an inner portion of dough within a distinct outer
layer of dough. In addition, none of the foregoing references
disclose rolling of multi-layered doughs to control the appearance
of flavored chips or other morsels in the baked product.
Europen patent application No. 31,718, Hong and Brabbs, filed Dec.
23, 1980 and published July 8, 1981, which is herein incorporated
by reference, describes the manufacture of laminated cookies which
combine different doughs to produce a product whose long-term
texture mimics that of freshly baked cookies. The cookies are made
from laminated dough structures formed by a variety of techniques.
These techniques include (1) enveloping an inner dough within a
layer of a second outer dough by hand crimping discs of outer dough
around a ball of inner dough, (2) layering sheets of two or more
alternating doughs previously cut to the appropriate size, (3)
layering large sheets of two or more alternating doughs and then
cutting into pieces, (4) laminating one or more doughs onto the top
of, or a portion of the top of, a distinct dough, (5) embedding
particles of one or more doughs into a distinct dough (6) winding
strands of one or more doughs onto the surface of a ball of a
distinct dough, (7) laminating alternating sheets of two or more
doughs, rolling, and slicing, or (8) co-extruding two or more
doughs on a Rheon.RTM. encrusting machine, by which inner and outer
doughs are co-extruded simultaneously and concentrically by the
machine, and the outer dough wraps around the inner dough and is
formed by an encrusting disk into a ball which is then baked.
It has now been determined that for some of the above laminating
techniques, rolling of the dough pieces prior to baking results in
cookies of improved appearance and quality. Rolling of the dough
pieces prior to baking is essential for any laminating technique
where the dough is not formed into the shape of a ball. The latter
includes, for example, co-extrusion of the doughs in a continuous
form which when cut yields rectangular segments or other shapes not
spherical or hemispherical in form, a sheet/deposit/sheet/cut
process wherein a first layer of dough is formed into a sheet upon
which inner dough pieces are deposited and covered with a second
sheet of the first or a third dough, and cut to a shape not
spherical or hemispherical in form, and other equivalent processes
which generate a dough piece which is not round, hemispherical, or
spherical in shape.
It has now been determined that cookies of the Hong and Brabbs type
made from processes generating dough pieces which are not round or
spherical in shape have different baking dynamics from cookies of
the Hong and Brabbs type made from rounded doughballs. The product
resulting from these processes can have thinner, crisper edges than
a typical drop cookie, or a cookie made by a rotary molder having
hemispherical cavities. This is due to the requirement of a finite
amount of perimeter space needed to seal the upper and lower dough
sheets or outer dough around the inner dough. A lack of inner dough
at the edges where the upper and lower dough sheets meet and seal
can result in the formation of thin, crisp edges during baking
which are often darker in color. Likewise, a lack of inner dough in
the corners of dough pieces of rectangular or other geometric
shapes yields the same undesirable result. These thin, crisp edges
contribute to product breakage and reduced consumer acceptance. At
the same time, use of laminating processes can result in decreased
visibility on the surface of the finished product of chips or
morsels contained in the inner dough. This also contributes to
reduced consumer acceptance.
Accordingly, it is an object of this invention to prevent the
formation of undesirable crisp, thin edges on laminated cookies
made from dough pieces not rounded, hemispherical, or spherical in
shape.
It is a further object of this invention to provide substantially
spherical or substantially hemispherical laminated dough pieces
made by extrusion, co-extrusion, sheet/deposit/sheet/cut, or other
equivalent methods.
It is a further object of this invention to provide a process for
rolling dough which provides substantially uniform encapsulation of
an inner piece of dough within a distinct outer layer of dough.
It is a further object of this invention to provide a process for
rolling dough which controls the degree of visibility of flavored
chips or other morsels in the baked product.
These and other objectives of the invention will be evident from
the following disclosure:
DISCLOSURE OF THE INVENTION
This invention provides a process for making an improved
crumb-continuous cookie having distributed therein discrete regions
of storage-stable crisp texture and discrete regions of
storage-stable chewy texture from a plurality of cookie doughs,
comprising the steps of:
(a) forming a laminate cookie preform from the doughs;
(b) rolling the preform; and
(c) baking the rolled preform.
The laminated cookie preforms are rolled into a substantially
spherical or substantially hemispherical shape to provide
essentially uniform encapsulation of the individual pieces of at
least one inner dough within at least one distinct outer layer of
dough. This prevents the formation of crisp edges on the cookies
during baking and results in more uniform color and resistnce to
breakage. The rolling step also reduces the need for complex
formulation changes to control dough spread for various oven types
and baking conditions. The rolling step also controls the exposure
and visibility of any flavored chips or other morsels.
Preferably, the dough preforms are rolled employing an orbiting cup
device comprising:
(1) a platen having one or more rows of one or more cup or cavity
units;
(2) a mechanical arm connected pivotally to the platen;
(3) a base support rotatably connected to the mechanical arm;
(4) means for moving the platen vertically and horizontally
simultaneously; and
(5) means for rotating the platen in a circular orbital motion
while simultaneously moving horizontally parallel to a continuously
moving conveyor belt supporting the dough pieces.
The size of the cup or cavity unit relative to the dough piece is
such that the outer top surface of the dough is smeared by the cup
to control visibility or exposure of morsels such as flavored
chips, nuts, and the like. Each dough piece is rolled only by a
single cup or cavity unit. Preferably, a plurality of dough pieces
are simultaneously rolled once by the platen which provides correct
alignment of the pieces on the continuously moving conveyor belt to
accommodate reasonable variation in dough spread during baking such
that contact of individual baked cookies is prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing
out and distinctly claiming the subject matter which is regarded as
forming the present invention, it is believed that the invention
will be better understood from the following description taken in
connection with the accompanying drawings in which:
FIG. 1 is a cross-sectional elevation of a co-extruded,
substantially spherical dough piece for a laminated cookie of the
Hong and Brabbs type.
FIG. 1A is a side elevation view of a co-extruded, substantially
spherical dough piece for a laminated cookie of the Hong and Brabbs
type.
FIG. 1B is a side elevation view of a baked laminated cookie of the
dough piece of FIG. 1A.
FIG. 2 is a cross-sectional elevation of a dough piece made by a
sheet/deposit/sheet/cut process for a laminated cookie of the Hong
and Brabbs type.
FIG. 2A is a side elevation view of a dough piece made by a
sheet/deposit/sheet/cut process for a laminated cookie of the Hong
and Brabbs type.
FIG. 2B is a side elevation view of a baked laminated cookie of the
dough piece made by the sheet/deposit/sheet/cut process of FIG.
2A.
FIG. 3 is a simplified bottom plan view of a single cup unit of an
orbiting cup device showing the rolling of a cut laminated dough
piece.
FIG. 4 is a simplified side elevation view of the single cup unit
shown in FIG. 3.
FIG. 5 is a simplified fragmentary elevation view of an orbiting
cup device for rolling cut laminated dough pieces.
FIG. 6 is a fragmentary bottom plan view of a portion of a platen
of multiple cavities of an orbiting cup device showing the cavity
interior and the position of the dough piece to be reshaped.
FIG. 7 is a simplified fragmentary top plan view of the orbiting
cup device shown in FIG. 5 for rolling cut laminated dough
pieces.
FIG. 8 is a schematic fragmentary side elevation view of a crank
device pivotally connecting platen 51 and platen 52 of FIG. 5
showing the orbiting motion of platen 51.
Like numbers of reference in the several figures indicate the same
items or components.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Dough preforms for laminated cookies of the Hong and Brabbs type
are distinct in shape depending upon the method of formation.
Examples of distinct shapes are shown in FIGS. 1 and 2 of the
drawings. FIG. 1 is a cross section of a co-extruded dough preform
which is substantially spherical in form, resembling a dough piece
made using a rotary molder. Inner dough 1 is uniformly encapsulated
within a distinct layer of discrete outer dough 2. FIG. 2 is a
cross section of a dough preform made by a sheet/deposit/sheet/cut
process. Inner dough or filling 3 is not uniformly encapsulated by
outer doughs 4 and 6. The preform is not spherical but instead has
an overlapping of the bottom and top dough sheets, 4 and 6, around
the perimeter. This overlapping area 5 forms a seal to enclose
inner dough deposit 3.
The distinct shapes of the dough preforms result in different flow
dynamics during baking. When the spherical dough piece of FIG. 1 is
baked it spreads via a "roll" type flow, as denoted by the arrows
in FIG. 1A. Dough near the diameter of the sphere rolls downward
onto the baking surface. When the dough piece of FIG. 2 is baked it
spreads via a "slide" type flow, as illustrated by the arrows in
FIG. 2A. The weight of the center deposit exerts a downward force
pushing the perimeter seal of bottom and top doughs outward. Thus,
the difference in baking dynamics of the two dough shapes provides
baked cookies of distinct shapes.
FIG. 1B is a cross section of a baked laminated cookie of the
substantially spherical, co-extruded dough piece of FIG. 1A. The
rolled outer edges result from the "roll" type flow of dough during
baking. FIG. 2B is a cross section of a baked laminated cookie of
the dough piece of FIG. 2A made by a sheet/deposit/sheet/cut
process. Thin crisp edges, denoted as 7, can occur at the cookie
perimeter corresponding to the overlapping seal area 5 of outer
doughs 4 and 6, as shown in FIG. 2. The thin edges are often darker
in color than the remainder of the cookie and usually easily
broken. The present invention provides a process for preparing
baked cookies of the preferred type illustrated in FIG. 1B from a
dough preform with the shape shown in FIG. 2A and from dough
preforms with other shapes that are not rounded, hemispherical, or
spherical.
Forming a Cookie Preform
The first step of the process of this invention is forming a cookie
preform from multiple doughs. Laminated dough structures, denoted
herein as cookie preforms, can be made from a variety of techniques
within the skill of those in the food production art. Of particular
interest herein are those processes which generate a dough
structure which is not rounded, hemispherical, or spherical in
shape but instead has edges, corners, and the like. Examples of two
such processes for the first step of this invention will be
described. One is a sheet/deposit/sheet/cut process and the other a
co-extrusion process.
A. Sheet/Deposit/Sheet/Cut Process
Forming a sheet of a first cookie dough by appropriate means is
required. Sugar, flour, water, and shortening, when combined in
almost any reasonable proportions, will produce a dough that can be
baked to form a cookie. In general, any cookie formulation which
produces an organoleptically acceptable cookie can be employed in
the practice of this invention. Those skilled in the art are
familiar with formula variations for controlling the rheology of
the dough to render it suitable for specific manufacturing
techniques, such as sheeting, rotary molding, extrusion, and other
commercial treatments. The formulations employed in the present
invention may also be optimized to provide a dough rheology
consistent with minimizing the formation of thin crisp edges in the
baked product.
The dough can be rolled into a sheet by hand by using a
conventional rolling pin. Alternatively, a dough mass can be passed
through a plurality of smooth parallel sheeting rolls to provide a
smooth coherent workable dough sheet. As the dough sheet passes off
the last roll in the series the dough is removed by a doctor blade
angularly disposed with respect to the surface of the last sheeting
roll. Doctoring angles up to about 180.degree. (the maximum
theoretical value) are preferably used. Two roll mills, three roll
mills, four roll mills, etc. can be used. When roll milling is
employed, differential roll speeds with a faster roll revolving
from at least 1% to 20% and preferably at least 3% faster than the
slowest roll are used. This is true because it has been found that
where differential roll speeds with a faster roll traveling at
least 1%, and preferably 3% greater speed than the slower roll are
employed, the sheet will conveniently be fed to the faster moving
roll. Roll gap can be adjusted to provide a sheet of the desired
thickness. As the sheet is doctored from the final roll in the
series, it is preferably transferred directly to a continuous band
or belt for further processing.
Preferably the dough is extruded under pressure through a wide
extrusion die of dimensions which will give the extruded sheet the
desired thickness and width. The same extrusion process is used for
forming the sheet of third cookie dough for appropriate placement.
The sheets are extruded onto a continuously moving belt or band,
which carries the extruded sheet to the next processing step. The
sheets are preferably wide enough to substantially cover the
manufacturing oven band and are from about 1 to about 3 mm.
thick.
Next, a second cookie dough or filling is deposited on the sheet of
first cookie dough. This is conveniently accomplished by use of a
standard rotary molder in the usual way. Deposits of dough in the
cavities of the rotary molder adhere to the tangentially moving
belt at the point of contact with the rotary molder, and are
transferred to the continuously moving sheet of first dough.
Alternatively, deposits of second cookie dough or filling can be
placed on the sheet of first dough by extrusion under pressure
through one or more extrusion dies or tubes positioned over the
sheet of first dough. In another embodiment of the process of this
invention, the second dough can be formed into individual pieces,
which can then be placed directly on the sheet of first dough. In
yet another embodiment of the process of this invention, the second
dough can be deposited on the sheet of first dough in the form of a
second sheet, using the process means employed for forming the
sheets of first and third doughs.
It is preferable in the practice of this invention to have
individual discrete deposits of second dough which are
substantially hemispherical, or substantially spherical in shape.
Clearly, spherical pieces of second dough can be used only when the
pieces are formed separately prior to being deposited upon the
sheet of first dough. However, when rotary molding or extrusion is
used, substantially hemispherical second dough pieces can be used.
The substantially hemispherical or substantially spherical shape of
the second dough pieces facilitates the later steps of the process
in providing a preferred dough shape around which the sheets of
first and third dough can be formed during the rolling step.
Then a sheet of a third cookie dough is formed and placed on top of
the deposits of second cookie dough. The dough can be extruded
under pressure through a wide extrusion die or passed through a
plurality of smooth parallel sheeting rolls as in the first step of
the process.
The layered doughs are then cut into cookie preforms. Preferably,
this is accomplished by a cutting mechanism which partitions the
layered doughs into discrete pieces in accordance with the deposits
of the second dough. Thus, only the first and third doughs are cut,
around the individual pieces of second dough. Tamping the top dough
sheet with a roller prior to cutting aids in molding it around the
deposits of the second dough. A continuous cutting mechanism which
moves synchronous to the dough sheets transported by the moving
belt or band can easily generate the desired cookie preforms.
Precise cutting of the composite dough pieces is not critical to
appearance because the cut pieces are reshaped during the rolling
step of the process. Preferably, the cutting mechanism cuts the
doughs and simultaneously crimps the edges of the upper and lower
doughs to seal the deposited dough within, with no damage to the
conveyor belt or band.
The preforms can be cut into any desired shape, such as circular,
square, rectangular, etc. The preferred shape is a hexagon or
similar shape which closely resembles a circle but results in no
generation of waste pieces of dough when cutting multiple preforms
concurrently.
In another embodiment of this process the cutting can occur prior
to layering, or assembling, of the doughs. The first and third
doughs can be sheeted and cut into the desired shapes followed by
insertion of the deposit of second dough between one piece of each
of the first and third doughs to form a cookie preform. The cutting
may also occur during dough layering. The first dough may be cut
after deposit of the second dough thereon, followed by layering
with a sheet or individual precut pieces of the third dough.
Alternatively, the first dough may be cut prior to deposit of the
second dough thereon, followed by deposit of the second dough, and
by layering with a sheet or individual precut pieces of the third
dough. A second cutting would be required in these alternatives if
the third dough is in sheet form. Preferably, the dough sheets are
cut simultaneously in one cutting step after layering of the
doughs.
B. Co-extrusion Process
An alternative process of the present invention for forming a
cookie preform of multiple doughs is to use a co-extrusion process.
Preferably, two or more distinct doughs are continuously extruded
from separate hoppers as concentric cylinders. A cylindrical-shaped
solid core of inner dough is surrounded by one or more layers of
cylindrical-shaped rings of distinct outer dough. The continuous
cylinder is then cut into pieces to form dough preforms.
Any suitable extrusion equipment can be employed. Typically the
extruder comprises two or more hoppers with feed rolls to channel
the flow of dough through a number of tubes called die cups or
through extrusion nozzles. These can have orifices of any desired
shape. Dough can be fed to the hoppers manually or mechanically by
pumps or other suitable means. As an alternative to multiple
distinct hoppers, separator plates can be inserted into a single
large hopper. Feeding the dough at a steady rate is important to
assure constant extrusion. Usually two or three feed rolls are used
and the distance of separation of the rolls is commonly adjustable.
Action of the feed rolls can be continuous or intermittent. Roll
speed should be such that the dough is not overheated through
excess friction. A change in the speed of one feed roll usually
results in a corresponding change in the speed of the others. The
dough is fed through an extrusion nozzle that has an orifice of any
of several desired shapes onto a conveyor belt. As previously
stated, it is preferred that the doughs be formed into continuous
concentric cylinders.
The continuous cylinder of doughs is then cut into individual dough
preforms. Preferably the dough is cut in a manner such that the
outer dough layer is smeared across the inner dough which would be
exposed by the cutting process to encapsulate or substantially
enrobe the inner dough piece within a layer of outer dough. When
sufficient cutting pressure is used to achieve the desired smearing
the resulting dough piece is often distorted in shape. A shape like
a rectangular pillow having four corner edges, comprised only of
outer dough, can result.
Rolling
Following assembly, the cookie preform is repositioned and rolled.
Preferably, it is rolled into a substantially hemispherical or
substantially spherical shape. This removes any edges or corners
formed during cutting and provides a layer of outer dough or doughs
substantially uniformly enrobing the deposited inner dough. The
crimped edges of the first and third doughs formed upon cutting
during the sheet/deposit/sheet/cut process are eliminated. Any
corners resulting from cutting co-extruded dough cylinders are
likewise eliminated. The preferred hemispherical or spherical
shapes, when baked, provide the desired "roll" type flow dynamics
as the cookie spreads. This reduces the need for complex
formulation changes to control dough spread for various oven types
and baking conditions. The resulting rounded edges in the baked
cookies are more uniform in color and more resistant to breakage
then the thin crisp edges or corners of cookies which can result
without the rolling step.
In a laminated dough product containing flavored chips, raisins,
nuts, fruit bits, coconut, cereals, or other edible morsels in the
inner dough, the rolling step controls the degree of visibility of
the morsels and helps randomize their distribution. Precession of
the axis of each individual dough preform results from rolling and
randomizes the distribution of morsels thereby improving the
appearance of the baked cookie. For example, dough preforms that
are cut from co-extruded concentric cylinders of doughs usually
have morsels exposed approximately 180.degree. apart at the points
where the doughs were cut. If baked without rolling these dough
preforms will result in cookies having at least two exposed morsels
at the edges about 180.degree. apart when viewed from the top.
Rolling the dough preforms causes the axis of each to precess and
reorients morsel distribution. The chips exposed by the cutting
step that are about 180.degree. apart usually are reoriented in a
manner such that only one appears at the top surface of the baked
cookie, and the other is at the bottom surface. Cookies baked from
the rolled dough preforms are improved in appearance due to a
random morsel distribution.
The rolling device, after rendering the enrobed inner dough in a
more uniform layer of distinct outer dough can also smear the top
surface of the outer dough to partially expose or increase the
visibility of the morsels in the inner dough. The morsels become
visible through the outer dough. Dough balls having a smeared top
surface of the outer layer upon baking generate cookies with a
greater level of appearance of morsels on the surface. The desired
degree of smearing of the top surface of the outer dough can be
achieved by regulating the viscosities of the inner and outer
doughs through formulation, mixing procedures, temperature, and
thickness. Alternatively, the morsels can be sprinkled onto the
cookie preform just prior to rolling. The rolling step will then
cause the morsels to penetrate into the outer dough layer as it
rolls the dough preform. The techniques can be combined if it is
desired to have morsels in both inner and outer doughs.
Any of the art disclosed equipment for rolling dough pieces to
substantially hemispherical or substantially spherical shape can be
modified for use in the rolling step of this invention.
Alternatively, the dough can be rolled by hand. In a preferred
mode, an orbiting cup device as depicted in FIGS. 5 through 8 is
employed.
The operation of a single cavity or cup unit of the preferred
orbiting cup device shown in FIGS. 3 and 4. The dough-shaping cup
is represented by 41. It has an external diameter 42 and a height
43. The initial position of the cookie preform within the cup is
represented by 44. It's position during rolling is represented by
45. The cup is orbited in a circular motion in the direction
indicated by arrow 31, thereby rolling the dough piece. The cup can
also rotate counterclockwise. The dough piece rotates within the
cup in the direction indicated by arrow 32.
Each individual cup or cavity unit, which itself does not revolve,
rolls the dough preform around against the interior unit surface,
forming it into a substantially hemispherical to substantially
spherical shape. The force of the orbiting motion reduces the
diameter of the dough preform, resulting in an increase in the
preforms height. This growth is restricted by the top of the
cavity. The periphery and top of the cavity form the product into
the desired shape and smear its top layer. The pre-ordained pattern
of movement can be controlled by any of several suitable means.
Preferred is control by computer. Arresting the orbiting motion at
a predetermined position provides correct placement of the preform
on a discharge belt for further processing.
The degree of visibility of morsels contained in the inner dough
achieved by smearing the top surface of the outer dough layer is
dependent upon the depth of the orbiting cup or cavity relative to
the size of the cookie preform, the number of orbits or rotations
made by the unit, the orbiter speed, and the cup or cavity interior
shape and finish. A variation of 0.10 inch (0.25 cm.) in unit depth
produces visible results. Shallow cups or cavities have a tendency
to tear open the top dough layer, while those too deep leave the
top layer untouched and morsels covered. For example, it has been
found that a cup or cavity depth of about 0.75 inch (1.9 cm.) is
preferred with dough pieces of about 0.6 inch (1.5 cm.) in height.
The number of orbits of the cup or cavity to achieve the desired
level of morsel visibility is dependent upon ambient temperature
and humidity, and viscosity of the dough. Dough viscosity can be
controlled through formulation and temperature.
Orbiter speed and cup or cavity shape and finish also affect the
appearance of the final product by changing the level of work input
into the dough piece. Orbiter speeds can range from about 10 to
about 200 rpm (revolutions per minute). A speed of about 60 to
about 120 rpm is preferred. Lower speeds require a greater number
of orbits, while high speeds can result in oval or
parallelogram-shaped dough pieces instead of the preferred
spherical or hemispherical. The orbit of the preform does not
coincide with the orbit of the cup or cavity, but is of a smaller
radius and is a function of the inside diameter of the unit as
shown in FIG. 3. Ovals, parallelograms, and other undesirable
shaped can also be generated by cup shape and finish. A very smooth
surface finish on the inside of the cup or cavity can result in
misshapen rolled preforms at high orbiter speeds dependent upon
dough rheology. A somewhat rough finish is preferable. Suitable
interior materials include Celcon.RTM., Plexiglass.RTM., and the
like. Any of several cup or cavity interior and exterior shapes can
be employed. In general, a hemispherical interior with a circular
edge is preferred.
Preferably, several cup or cavity units are operated
simultaneously. FIG. 6 illustrates a portion of a multi-unit
platen. The platen can be comprised of one or more single cup units
or may be a solid plate containing one or more cavities. The
individual units do not revolve independently about their
individual axes. The platen of FIG. 6 is viewed looking into the
cup or cavity interiors, showing the adjacent location of the
individual cavities. An individual cavity is denoted as 61. The
edges of the cavities are preferably circular in shape but can be a
multi-sided configuration similar to a circle such as hexagonal.
This minimizes space between cavities, permits adjacent nesting of
units, and minimizes the possibility of dough being between the
cavities or cups. When the cavity edges are hexagonal or
multi-sided, they transition to a rounded hemispherical shape, and
any corners present are rounded. The interior cup shape is one
factor that affects control of the visibility of chips or morsels
in the inner dough via smearing of the outer dough layer. The
interior cup shape also affects precession of the axis of the dough
piece during rolling. The distance 62 between unit centers is
designed to accommodate a reasonable variation in dough spread
during baking. The preferred orientation 63 of the hexagon-shaped
dough preform within the individual cavity or cup unit is not
crucial. A flat circular area 64 can occur at the apex of each
unit. A unit with a hemispherical interior with a circular edge
results in greater visibility of chips through increased smearing
of the top surface of the outer dough layer than is achieved by one
that is hexagonal on the edge which transitions to a substantially
hemispherical shape. The former decreases tearing or shredding of
the dough. The outside of the units can be hemispherical, hexagonal
or other similar shapes and can be distinct in shape from the
interior.
As illustrated by FIGS. 5 and 7, a large platen 51 having one or
more rows of one or more cup units or cavities, is lowered by
mechanical arm 53 over one or more dough preforms supported by
moving belt 54 such that each individual dough preform is covered
by one individual cavity or cup unit. Platen 51 is then rotated in
a circular orbital motion while simultaneously continuously moving
horizontally a distance 71 in the form of a flat spiral thereby
rolling the dough pieces. Platen 51 is orbited by means of a
crank-type mechanism illustrated in FIG. 8. It is pivotally
connected to platen 51 and to a distinct platen 52. Platen 52 is
connected pivotally to mechanical arm 53 and does not orbit.
Platens 51 and 52 move horizontally in the direction of movement of
the conveyor belt a distance 71, are elevated slightly to clear the
dough pieces, move horizontally in the opposite direction a
distance 71, and are lowered over different dough pieces to repeat
a continuous cycle. Platen 51 does not have to be in direct contact
with the belt transporting the dough pieces to effectively roll the
cookie preforms, but is preferably raised slightly above the belt
surface. However, this gap should be minimized to avoid extruding
dough into the gap. Platen 52 can be any number of distinct shapes
such as a rectangular plate, a framework of arms, or other
equivalent connecting means between mechanical arm 53 and orbiting
platen 51.
The motion of platens 51 and 52 and mechanical arm 53 is controlled
by computer 56. The number of orbits can be varied within a fixed
stroke distance or, alternatively, the stroke distance can be
varied according to the number of orbits. The number of orbits per
stroke and the stroke distance are adjusted for the specific
product depending upon the viscosity or rheology of the dough,
level of work input into the dough desired, and degree of chip
visibility and randomization desired. At the completion of each
stroke, the orbiting motion is arrested at a predetermined position
which provides correct placement of the dough preforms on belt 54
for further processing. Platens 51 and 52, which move continuously,
are then raised above the dough pieces and returned to the initial
stroke position to begin a new cycle. The orbital motion can be
reversed during the return stroke. The belt supporting the dough
preforms continuously advances during operation of the orbiting cup
device.
Base support 55 is rotatably connected to mechanical arm 53.
Mechanical arm 53 is preferably jointed at points 57, 58 and 59 in
order to move platens 51 and 52 horizontally and vertically
simultaneously during the working cycle. The platens can be
transferred between conveyor belts and positioned for easy cleaning
and maintenance.
The foregoing illustrates one preferred mode of practicing the
rolling step of this invention.
Baking
The final step of the process of this invention is baking of the
cookie preforms. Baking conditions will vary over a considerable
range dependent upon the dough compositions, equipment utilized,
and desired characteristics in the final product.
Summary
It can be appreciated that still other embodiments or executions,
from an apparatus standpoint, of this invention can be devised
without departing from its scope and spirit and without losing its
advantages. In particular, the rolling process, however practiced,
results in different flow dynamics during baking, which reduces the
complexity of formulation required in attempting to control dough
spread during baking. In addition, precise cutting or forming of
composite dough pieces becomes less critical for making cookies
with good appearance, since the pieces are reshaped during the
rolling process. The resulting rounded edges in the baked cookies
show more uniform color and are more resistant to breakage than the
thin, crisp edges which can occur on cookies made directly from
unrolled preforms. Also for a product containing flavored chips or
other morsels, the appearance of the morsels in the baked cookie
can be controlled.
Industrial Applicability
The following embodiments illustrate the practice of this
invention, but are not intended to limit it. CL EXAMPLE 1
______________________________________ Ingredients Percent by
Weight ______________________________________ First Dough
Hydrogenated vegetable shortening 16.5 Sugar 31.1 High fructose
corn syrup 5.1 Flour 37.4 Flavor and minor ingredients 1.0 Water
8.9 Second Dough Hydrogenated vegetable shortening 15.5 Sugar 9.5
High fructose corn syrup 26.4 Flour 24.6 Flavoring and minor
ingredients 3.7 Chocolate chips 20.3 Third Dough Hydrogenated
vegetable shortening 16.5 Sugar 31.1 High fructose corn syrup 5.1
Flour 37.4 Flavor & minor ingredients 1.0 Water 8.9
______________________________________
The first dough was formed by mixing the ingredients in the
following order: the high fructose corn syrup, water, and liquid
flavor ingredients were mixed, then the shortening added and the
mixture creamed. The sugar was then added, mixing continued, and
then the flour and other minor dry ingredients were added.
The second dough was prepared by mixing the water and liquid
flavoring material with the high fructose corn syrup. The
shortening was then added and the mixture creamed until the
shortening began to crystallize. The sugar was then added, and the
mixture is creamed again. All the dry ingredients were then mixed
in.
The third dough was prepared in the same manner as the first
dough.
The first dough was rolled to a sheet 1-2 mm. in thickness. About
10 grams of the second dough was formed into a ball (substantially
spherical) which was placed on top of the first dough. The third
dough was then rolled to a 1-2 mm. sheet and placed on top of the
ball of second dough. The sheets of dough were then cut in a
hexagon shape about 4 cm. in diameter around the deposits of the
second dough. The edges of each were crimped manually to seal the
ball of second dough between the hexagons of first and third
doughs. One half of the resulting composite dough pieces were
rolled by hand to yield a substantially spherical cookie preform.
The remainder were baked as hexagon-shaped preforms. Upon baking at
about 305.degree. F. to 310.degree. F. (152.degree. C. to
154.degree. C.) for about 81/2 minutes, a roll type flow was
obtained resulting in a cookie similar to a drop or rotary molded
type cookie without atypical thin, crip edges for the rolled
preforms. The rounded edges were uniform in color. The level of
appearance and distribution of chocolate chips upon the surface of
the baked cookies was acceptable. The cookie diameters averaged
2.36 inches (5.99 cm.). For the hexagon-shaped preforms a sliding
type of flow was obtained resulting in cookies with thin crisp
edges with variation of color in the edges. The appearance of
chocolate chips on the surface of the baked cookie was minimal or
nonexistent. The cookie diameters averaged 2.48 inches (6.30 cm.).
The above process was repeated two additional times with similar
results.
EXAMPLE 2
______________________________________ Ingredients Percent by
Weight ______________________________________ First Dough
Hydrogenated vegetable shortening 16.7 Sugar 30.8 High fructose
corn syrup 4.6 Molasses (26 .+-. 4% invert sugar) 1.5 Baking Soda
0.5 Flour 37.4 Flavor and minor ingredients 1.0 Water 7.5 Second
Dough Hydrogenated vegetable shortening 15.5 Sugar 9.5 High
fructose corn syrup 26.4 Baking Soda 0.5 Flour 24.2 Flavor and
minor ingredients 3.6 Chocolated chips 20.3 Third Dough
Hydrogenated vegetable shortening 16.7 Sugar 30.8 High fructose
corn syrup 4.6 Molasses (26 .+-. 4% invert sugar) 1.5 Baking soda
0.5 Flour 37.4 Flavor and minor ingredients 1.0 Water 7.5
______________________________________
The first dough was formed in the following manner. The baking soda
was dissolved in the water and combined with the flavor and
molasses. The combination was mixed with the high fructose corn
syrup. The shortening was added and the mixture creamed. Half of
the sugar was mixed in, the flour and minor ingredients were added
and mixed, and the remainder of the sugar added and mixed.
The second dough was prepared by first mixing the high fructose
corn syrup, flavor, and baking soda. The shortening was added and
the mixture creamed. Half of the sugar was mixed in, the flour and
minor ingredients added and mixed, and the remainder of the sugar
was added and mixed. Finally, the chocolate chips were mixed
in.
The third dough was prepared in the same manner as the first
dough.
The first dough was extruded into a sheet about 2-4 mm. in
thickness onto a continuously moving belt. Discrete hemispherical
deposits of the second dough of about 12.5 grams in weight were
placed upon the sheet of first dough in an ordered pattern by means
of a rotary molder. The third dough was extruded into a sheet about
2-4 mm. in thickness and placed over the lower sheet and deposits.
The top sheet was tamped into place with a roller of about 6 inches
in diameter. The dough sheets were cut around the deposits of
second dough to yield multiple hexagon shaped cookie preforms. The
preforms were then repositioned to provide proper alignment for
rolling. The preforms were rolled to substantially hemispherical
shape using an orbiting cup device as previously described. The
second dough deposit was substantially uniformly encapsulated
within an outer layer of the first and third doughs. An orbiting
cup device having a platen of several cavity units, each having a
hemispherical interior and hexagonal exterior, with a depth of 0.75
inch (1.9 cm.) rotating at about 105 rpm rolled several dough
preforms simultaneously and smeared the top surface of the outer
layer of dough to increase the visibility of or to expose the
chocolate chips in the inner dough. Arresting the orbiting motion
at a predetermined position provided correct placement of the
preform on the discharge belt. The rolled preforms were transferred
to an oven band and baked for about 8.5 minutes in a recirculating
indirect gas-fired oven. The upper zones were maintained at a
temperature of 330.degree. F..+-.10.degree. F. (165.5.degree.
C..+-.5.5.degree. C.) and the bottom zones were maintained at a
temperature of about 280.degree. F..+-.5.degree. F. (137.8.degree.
C..+-.2.8.degree. C.). Upon baking, a roll type of flow dynamics
was obtained resulting in cookies similar to a drop or rotary
molded cookie without atypical thin crisp edges. The cookies had an
average diameter of from about 2.0 to about 2.2 inches (5.1 to 5.6
cm.) and an average weight of from about 11.5 to about 12.0 grams.
The rounded edges were uniform in color and an acceptable level and
distribution of appearance of chocolate chips was obtained.
EXAMPLE 3
The hexagon-shaped cookie preforms of Example 2 were sprinkled with
chocolate chips just prior to rolling. The preforms were rolled to
substantially spherical shape using the orbiting cup device as
previously described. The added chips penetrated into the outer
dough layer. The rolled preforms were transferred to an over band
and baked as in Example 2. The baking dynamics and resulting baked
cookies were similar to those in Example 2 except that a higher
level of chip visibility on the cookie surfaces was achieved.
EXAMPLE 4
______________________________________ Ingredients Percent by
Weight ______________________________________ First Dough
Hydrogenated vegetable shortening 16.5 Sugar 30.4 High fructose
corn syrup 4.5 Molasses (26 .+-. 4% invert sugar) 1.5 Flour 37.4
Baking soda 0.5 Flavor and minor ingredients 0.5 Water 8.6 Second
Dough Hydrogenated vegetable shortening 15.5 Sugar 9.5 High
fructose corn syrup 26.4 Flour 24.6 Baking soda 0.4 Flavor and
minor ingredients 3.3 Chocolate chips 20.3
______________________________________
The two doughs were mixed as in Example 2. The doughs were then
separately manually fed into the two distinct hoppers of a
co-extrusion machine, Model No. DDP 200-9005, available from Bepex
Hutt GmbH, Postfach 9, Daimlerstrasse 9, D-7105 Leingarten, West
Germany. The dough was fed through the machine via feed rolls and
extruded through a nozzle onto a conveyor belt. The extruder formed
the doughs into continuous concentric cylinders such that the
second dough was surrounded by an outer layer of the first dough.
The dough cylinder was then cut into individual dough cookie
preforms so that the outer dough layer was smeared across the inner
dough which would have been exposed by the cutting process. The
cookie preforms were pillow-shaped rectangular pieces with the
second dough enrobed in a nonuniform layer of first dough. The
preforms were then repositioned to provide proper alignment for
rolling. The preforms were rolled to substantially hemispherical
shape using an orbiting cup device as previously described. The
second dough was substantially uniformly enrobed within an outer
layer of first dough. An orbiting cup device having a platen of
several cavity units, each having a hemispherical interior and
hexagonal exterior, with a depth of 0.75 inch (1.9 cm.) rotating at
about 105 rpm rolled several dough preforms simultaneously and
smeared the top surface of the outer layer of dough to increase the
visibility of or to expose the chocolate chips in the inner dough.
Arresting the orbiting motion at a predetermined position provided
correct placement of the preform on the discharge belt. The rolled
preforms were transferred to an oven band and baked for about 8.5
minutes in a recirculating indirect gas-fired oven. The upper zones
were maintained at a temperature of 330.degree. F..+-.10.degree. F.
(165.5.degree. C..+-.5.5.degree. C.) and the bottom zones were
maintained at a temperature of about 280.degree. F..+-.5.degree. F.
(137.8.degree. C..+-.2.8.degree. C.). Upon baking, a roll type of
flow dynamics was obtained resulting in cookies similar to a drop
or rotary molded cookie without atypical thin crisp edges. The
cookies had an average diameter of from about 2.0 to about 2.2
inches (5.1 to 5.6 cm.) and an average weight of from about 11.5 to
about 12.0 grams. The rounded edges were uniform in color and an
acceptable level of appearance and distribution of chocolate chips
was obtained.
* * * * *